Inorganic composite coatings comprising novel functionalized acrylics

Abstract

Disclosed is a sol-gel coating composition comprising: one or more silane hydrolysis promoting acids; at least one silanol precursor; and an acrylic-based co-polymer comprising nitrogen-containing organic functional groups, and methods of making and using same, as well as metals coated using the compositions.

Description

RELATED APPLICATIONS[0001]NONE.STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH[0002]NONEFIELD OF THE INVENTION[0003]This invention relates generally to anti-corrosion protective coatings and, more particularly, to anti-corrosion protective coating compositions that are sol-gel compositions comprising one or more silanol precursors, a silane hydrolysis promoting acid and an acrylic-based co-polymer comprising nitrogen-containing organic functional groups and methods of making and using same, as well as metals coated using the compositions.BACKGROUND OF THE INVENTION[0004]Untreated metal surfaces are subject to corrosion which can lead to rust development, weakening, discoloration and failure of the surface. Thus metal substrates are typically treated by a variety of methods to make the surface less reactive and more corrosion resistant. In addition, metal surfaces are often subsequently coated with decorative or additional protective coatings such as resin coatings, primers, paints ...

AI Technical Summary

Benefits of technology

The patent states that adding nitrogen-containing groups to an acrylic-based co-polymer improves its ability to resist corrosion compared to a coating without these groups. This means that the nitrogen-containing groups make the coating more durable and better at preventing damage caused by corrosion.

Problems solved by technology

Untreated metal surfaces are subject to corrosion which can lead to rust development, weakening, discoloration and failure of the surface.

The transfer of electrons from the metal to the oxygen at electrocatalytic sites leads to formation of various metal oxide corrosion products.

They are not desirable for medium- or long-term corrosion protection alone, and when combined with other coatings make the surfaces unpaintable and by the nature of their handling are not suitable for a final consumer product.

Phosphate conversion coatings provide better corrosion protection and paintability, but require quite acidic conditions to operate, which is not desirable due to difficulty in handling the application chemicals, more troublesome waste treatment due to sludge generation, and extra wear on equipment.

Chromium-containing coatings and passivates are not desirable due to negative environmental considerations and more troublesome waste treatment.

Highly acidic treatments also tend to degrade processing equipment and pose concerns with worker exposure.

Another issue for coatings is the development of yellowing or a yellow hue in the coating after heat treatment of a coated substrate or other common treatments including exposure to alkaline cleaners, phosphating solutions or solvents.